BỘ GIÁO DỤC VÀ ĐÀO TẠO

TRƯỜNG ĐẠI HỌC SƯ PHẠM KỸ THUẬT TP. HCM

KHOA ĐÀO TẠO QUỐC TẾ

SUBJECT:
AUTOMOTIVE ELECTRICAL AND
ELECTRONIC SYSTEMS

TOPIC: ALTERNATOR

TEACHER: Trần Đăng Long

Student name Student ID

Lê Hoàng Huy - 22145028
Hồ Minh Tân - 22145063
Nguyễn Thanh Minh - 22145044

Ho Chi Minh City, November 2024

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Trần Đăng Long

LỜI NÓI ĐẦU.....................................................................................................2
I. Introduction to the Alternator System in Cars.........................................4
1. Structure of a car generator...................................................................4
2. Functions of Automotive Alternators....................................................9
II. Operating principle of car generator.....................................................10
1. When the ignition is turned to the ON position and the engine
has not started............................................................................................10
2.Voltage is lower than the regulated voltage.........................................11
3.Voltage is higher than the regulated voltage .......................................11
III. Signs and how to check when a car alternator is broken..................12
1. Signs of a broken car alternator...........................................................12
2. How to check car generator..................................................................13
3. Causes of generator failure...................................................................14
CONCLUSION

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 LỜI NÓI ĐẦU

In the present era when our country is implementing an open-door

policy of integration with other countries, especially when our country
joins the WTO, science and technology are the key issues for our country
to keep up with developed countries and maintain a stable economy. And
automobile engineering is one of the inevitable issues when automobile
technology in the world is developing strongly. Along with that
development, the requirement for automobile technicians is increasingly
to improve their skills.

Currently, the inspection, disassembly, and repair of generators is

very common, but in the automobile industry, generators are
indispensable. Therefore, the restoration and repair of generators is an
important issue that automobile technicians should know and learn. As a
student of Ho Chi Minh City University of Technical Education and a
future technician, I have also received the topic: Building a process for
inspecting, disassembling, and repairing ''Generators''.

I find this an interesting and very practical topic. With my own

efforts, my own understanding and the help of teachers and friends,
especially the enthusiastic guidance and instruction of Mr. Tran Dang
Long, I have now completed this topic. Although I have tried my best,
due to lack of experience and limited understanding, it is inevitable that
there will be shortcomings in the topic. I look forward to the guidance of
teachers and the comments of friends inside and outside the class. I
sincerely thank you!

In the current context, when the automobile industry is growing

strongly, mastering and understanding deeply the technical components
of the car becomes extremely important. One of the indispensable
essential parts in any car is the generator. The generator plays an
important role in providing a stable power source for electronic systems
and equipment on the car.

When the car is operating, the generator must ensure sufficient

power supply to maintain the operation of the engine, lighting system, air
conditioning system, and many other devices. Understanding the

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structure, operating principles and how to maintain and repair the
generator not only helps improve the performance of the car but also
contributes to prolonging the life of the equipment on the car.

We will delve into the study of the structure and operating

principles of the generator on the car. In addition, we will also mention
the methods of checking, maintaining and repairing generators to ensure
their stable and efficient operation. Hopefully, this essay will bring useful
and practical knowledge to technicians, students majoring in mechanical
engineering and those interested in the automotive field.

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I. Introduction to the Alternator System in Cars

The alternator system in a car is an essential component that provides

electrical power to various electrical devices in the vehicle, such as
headlights, air conditioning systems, radios, engine control systems, and
other electronic devices. Unlike devices that use external power sources
like batteries, the alternator in a car is responsible for converting
mechanical energy from the engine into electrical energy, ensuring that
these systems operate efficiently.

The alternator in a car typically works on the principle of electromagnetic

induction, generating alternating current (AC), which is then converted
into direct current (DC). This system not only recharges the battery but
also powers the car’s electrical systems while the engine is running.

1. Structure of a car generator

The alternator system in a car consists of several key components, each

playing an important role in generating and maintaining a stable power
supply:

Hình 1. Structure and components of car generator

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 a. Rotor:

Rotor: is essentially a magnet inside the stator coil that helps generate a
changing magnetic field, thereby creating a changing magnetic field
inside the stator coil. This coil is wound around 6 pairs of pole cores, that
is, 12 poles. When the electromagnetic field is created, when an electric
current runs inside, the temperature will be generated in the Rotor due to
the increasing current intensity when the Rotor rotates. Depending on the
type of generator, some manufacturers can equip an additional coaxial fan
or simply add an outer shell with good heat dissipation material.

Hình 2. Rotor part of the generator

b. Stator:

The stator is the stationary part of the alternator, containing

coils of wire that are placed within the rotor’s magnetic field.
As the rotor turns, the changing magnetic field induces an
electric current in the stator’s coils. This current is alternating
current (AC).

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 Hình 3. Stator part of the generator

Carbon brushes and commutators: people use metal grabphites to

make carbon brushes with the purpose of reducing resistance as well as
contact resistance and it also helps prevent corrosion.

Hình 4. Carbon brushes and commutators part of the generator

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c. Rectifier:

The alternating current generated by the rotor and stator cannot

be directly used by the car’s electrical systems, which require
direct current. The rectifier (comprising diodes) converts the AC
into DC, which is supplied to the car’s electrical components.

Hình 5. Rectifier part of the generator

d. Voltage Regulator:

This is the part that helps to regulate the generator and adjust the
voltage to the most stable level. The operating principle of the car
generator has many ways to generate electricity, but in the car
generator, people use coils and magnets to generate current inside the
coil. The electromotive force generated inside the coil is greater when
the number of turns is greater, the magnet is stronger, the rotation

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speed of the magnet or motor is faster. When the magnet moves closer
to the coil, the flux will increase through the coil. On the contrary, if it
is far from the coil, the magnetic field line passing through the coil
will be reduced. The coil does not want the magnetic flux passing
through it to change, so it will try to create magnetic flux in the
direction that opposes the changes that occur. These are things Based
on the theory of Basic Physics. In reality, permanent magnets will be
replaced by new electromagnets. When starting the car, it will take
electricity from the battery and at the same time be equipped with a
steel core to increase the magnetic flux passing through the coil. The
magnetic flux loop will make the magnetic flux change continuously.

Hình 6. Voltage Regulator part of the generator

e. Battery:

The battery stores DC power and provides energy when the

engine is not running, such as when starting the car. When the
engine is running, the alternator recharges the battery and
supplies power to the electrical systems.

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 Hình 7. Battery

f. Wiring and Connectors:

The wiring connects all components of the alternator system and

supplies power to various electrical devices within the vehicle.
These wires must be designed to withstand the vehicle’s
operating conditions.

2. Functions of Automotive Alternators

Supply power to electrical devices in the vehicle: Generators provide
power to devices such as lights, radios, air conditioners, fans, and
electronic systems in the vehicle when the engine is running.
Battery Recharge: The generator also has the function of recharging the
car's battery. When the motor is running, the generator generates direct
current (DC) and provides power to recharge the battery.
Maintains a stable power system: Generators help maintain a stable
power supply for the devices in the vehicle, especially in situations when

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large power consuming devices (such as air conditioners, headlights,
etc.) are operating.
The car engine does not generate electricity. It can only generate work,
supporting the movement of the car. Therefore, the car generator is an
important part for the operation of the car. The car generator generates
electricity for the battery and other devices in the car's electrical system.

The car generator has 3 main functions: generating electricity, regulating

output voltage and changing alternating current into direct current.
Specifically as follows:

Generating electricity: When the car engine starts, the generator will be
activated and generate continuous current. This helps the devices on the
car such as: charging system, control system, screen and speakers, have
enough power to operate stably. Thanks to the generator, the energy on
the car is also maintained and provided to the parts effectively.

Adjusting output voltage: The car generator is mounted near the engine,
driven by the crankshaft. Therefore, the current will depend on the
rotation speed of the car engine. The generator has the function of
adjusting the stable current, avoiding the phenomenon of strong and weak
currents affecting the operation of electrical equipment on the car.

Converting alternating current into direct current: Normally, the battery

transmits direct current to electrical equipment on the car. The car
generator has the function of rectifying and adjusting the current from
alternating current to direct current to supply the car's electrical system.

II. Operating principle of car generator

1.When the ignition is turned to the ON position and the engine has

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not started
When the ignition switch is turned to the ON position, battery voltage is
applied to terminal IG. As a result, the M.IC circuit is activated and
Transistor Tr1 is opened, causing field current to flow in the rotor coil. In
this state, current has not been generated, so the voltage regulator reduces
the battery discharge to the lowest possible level by intermittently
switching on and off Transistor Tr1. At this time, the voltage at terminal
P = 0 and the M.IC circuit will determine this state and transmit a signal
to Transistor Tr2 to turn on the charging indicator light.

Hình 9.Diagram of the working principle of the regulator without

starting the engine.
2.When the generator is generating electricity (voltage is lower than
the regulated voltage)
The motor starts and the generator speed increases, the M.IC circuit
opens Tranzisto Tr1 to let the field current pass through and thus the
voltage is immediately generated. At this time, if the voltage at terminal
B is greater than the battery voltage, current will enter the battery to
charge and supply electrical devices. As a result, the voltage at terminal P
increases. Therefore, the M.IC circuit determines the power generation
status and transmits a signal to close Transistor Tr2 to turn off the
charging indicator light.

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 Hình 8. Diagram of the working principle of the voltage
regulator when the generator is generating electricity (voltage is lower
than the regulated voltage).

3.When the generator is generating electricity (voltage is higher than

the regulated voltage)
If Transistor Tr1 continues to open, the voltage at terminal B increases.
Then the voltage at terminal S exceeds the regulated voltage, the M.IC
circuit determines this condition and closes Transistor Tr1. As a result,
the field current in the rotor winding gradually decreases through the
reverse electromagnetic absorption diode D1 and the voltage at terminal
B (generated voltage) decreases. Then if the voltage at terminal S drops
to the adjusted value, the M.IC circuit will determine this condition and
open Transistor Tr1. Therefore, the field current of the rotor winding
increases and the voltage at terminal B also increases. The IC voltage
regulator keeps the voltage at the S terminal (voltage at the battery
terminal) stable (regulating voltage) by repeating the above processes.

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 Hình 10.Diagram of the working principle of the voltage regulator when
the generator is generating electricity (voltage is higher than the regulated
voltage).

III. Signs and how to check when a car alternator is broken

1. Signs of a broken car alternator
Here are the signs of a damaged car alternator

The car is difficult to start: If you find the car is difficult to start, it is
likely that the car battery is weak and dead. There are many reasons for
this situation, the most common is due to a malfunctioning alternator
because a malfunctioning alternator will not be able to charge the battery.
When this happens, turn off unnecessary electrical equipment such as the
entertainment screen, speakers, and car air conditioner. Then quickly take
the car to the garage for inspection, otherwise the car will stall in the
middle of the road and cannot be driven.

The battery indicator light turns on: According to the principle, after
starting the engine, the indicator lights on the dashboard will turn off to
signal that the systems are operating normally. In case the car has moved
but the indicator light does not turn off, this is a sign that the system is

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having problems. When the battery is weak, damaged, or the battery
system has a problem, it will light up continuously to notify.

Weak car lights: When the car's generator has a problem, not only will the
battery not be fully charged, but the electrical equipment on the car will
also be affected, which means the headlights will be dimmer than usual,
with the lights flickering sometimes dim and sometimes bright.

The car makes strange noises: There are many reasons why the car makes
strange noises in the engine compartment, including if the car makes a
rattling noise, it is very likely that the belt or pulley of the generator is
damaged. A damaged belt or pulley can cause the generator to not be able
to drive well or even not work.

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2. How to check car generator
Method 1:
That is to directly check the car generator, usually there is a generator
voltage meter on the car to check the operating status of the generator.
First, start the engine and turn on all electrical equipment on the car such
as air conditioner, DVD screen, speakers, headlights, then step on the gas
to increase the engine speed to about 2,000 rpm, then observe the voltage
on the meter increase or decrease, compare the change of voltage before
and after.
Method 2:
It is to check through the battery, you can check the operating status of
the car generator by measuring the battery voltage. Step 1 is to measure
the battery voltage when the car is off. When the car is off, use a
voltmeter to measure the battery voltage. If the measured voltage is equal
to or greater than 12V, it means the battery is normal. If the voltage is less
than 12V, it means the battery is weak and needs to be replaced. After
measuring, remove all the measuring wires. Step 2 is to measure the
battery voltage when the car is on. Start the car and reconnect the
measuring wires to the battery. If the measured voltage is higher than the

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voltage when the engine is off, about 13.4V to 14.2V, the generator is still
working well. If the measured voltage is lower than the voltage when the
engine is off, this is a sign that the car generator is weak or
malfunctioning and needs to be checked, repaired or replaced.

3. Causes of generator failure

There are many reasons why the car generator is damaged, the most
common of which are the following errors:
Rotor coil is damaged: the cause may be due to a broken excitation coil,
short circuit, ground contact, melted copper core insulation glue... The
error is often at the beginning of the excitation coil to the contact ring.
This causes the magnetic flux to decrease, the voltage is low, and the
current does not escape to the external circuit.
Stator coil is damaged: the cause may be due to a broken stator coil,
ground contact.
Carbon brush problem: the cause may be due to the contact ring being
chemically oxidized and covered with oil, the carbon brush is warped, the
carbon blower spring is no longer good

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Conclusion

The alternator system in cars plays a vital role in maintaining the

operation of electrical systems in the vehicle and ensuring that the battery
remains sufficiently charged to start the engine and power electrical
devices. Not only does the alternator help improve fuel efficiency, but it
also contributes to reducing environmental impact by optimizing energy
use. Regular maintenance and inspections are essential to ensure the
longevity and optimal performance of the alternator system, making it a
crucial component of modern automobiles.

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